Method for manufacturing a composite guide vane having a metallic leading edge

ABSTRACT

A method of manufacturing a composite guide vane with a metallic leading edge includes receiving a layup of fiber-reinforced composite sheets of continuous, substantially parallel and non-interlaced fibers impregnated with a resin. A vane body is formed from the layup of sheets. The vane body includes a body mid portion for interacting with a fluid and a body end portion. The method includes applying a metallic sheath on part of the vane body. The metallic sheath defines a leading edge of the guide vane. The method includes overmolding a head or a foot of the guide vane onto part of the vane body and onto part of the metallic sheath.

TECHNICAL FIELD

The disclosure relates generally to gas turbine engines, and moreparticularly to composite guide vanes.

BACKGROUND

Guide vanes of a gas turbine engine typically include an airfoil bodythat is disposed between a radially inner platform defined on a foot ofthe guide vane and a radially outer platform defined on a head of theguide vane. Guide vanes are typically arranged in rows and serve toguide the gas stream passing through the engine to a desired speed andangle. Guide vanes must also withstand erosion, abrasion, and impactfrom foreign objects that may enter the gas turbine engine. Guide vanesare generally made of metal, but it is becoming desirable to make themout of composite materials to reduce their weight. Unfortunately,methods of fabricating guide vanes out of composite materials can becomplex, require expensive tooling and are time consuming. Improvementis desirable.

SUMMARY

In one aspect, the disclosure describes a method of manufacturing acomposite guide vane of a gas turbine engine. The method comprises:receiving a body made of a fiber-reinforced composite material, the bodyincluding a body mid portion for interacting with a fluid and a body endportion; applying a metallic sheath on part of the body, the metallicsheath including: a sheath mid portion applied to the body mid portionto define a leading edge of the guide vane; and a sheath end portionapplied to the body end portion; and overmolding a head or a foot of theguide vane onto the body end portion and onto the sheath end portion.

In another aspect, the disclosure describes a method of manufacturing acomposite guide vane of a gas turbine engine. The method comprises:receiving a layup of fiber-reinforced composite sheets of continuous,substantially parallel and non-interlaced fibers impregnated with athermoplastic resin; forming a vane body from the layup of sheets, thevane body including a body mid portion for interacting with a fluid anda body end portion; applying a metallic sheath on part of the vane body,the metallic sheath defining a leading edge of the guide vane; andovermolding a head or a foot of the guide vane onto part of the vanebody and onto part of the metallic sheath.

In another aspect, the disclosure describes a guide vane for a gasturbine engine. The guide vane comprises: a body made of afiber-reinforced composite material, the body including a body midportion for interacting with a fluid and a body end portion; a metallicsheath applied to part of the body, the metallic sheath including: asheath mid portion applied to the body mid portion and defining aleading edge of the guide vane; and a sheath end portion applied to thebody end portion; and a head or foot overmolded onto the body endportion and onto the sheath end portion.

In another aspect, the disclosure describes a method of manufacturing avane body of a guide vane of a gas turbine engine. The method comprises:receiving a precursor including layers of substantially parallel andnon-interlaced reinforcement fibers embedded in a resin; compressionmolding the precursor into a preform of a core of the vane body; andovermolding a skin of the vane body on the preform of the core.

In another aspect, the disclosure describes a method for manufacturing avane body of a guide vane of a gas turbine engine. The method comprises:preparing a precursor including a layup of fiber-reinforced compositesheets of long, substantially parallel and non-interlaced fibersimpregnated with a first resin; stamping the precursor into a preform ofa core of the vane body; and overmolding a skin of the vane body on thepreform of the core with a second resin reinforced with randomlyoriented short fibers.

In a further aspect, the disclosure describes a guide vane of a gasturbine engine. The guide vane comprises: a core of an airfoil-shapedvane body, the core including layers of long and substantiallynon-interlaced reinforcement fibers embedded in a first resin; and askin of the airfoil-shaped vane body, the skin at least partiallyencapsulating the core and including a second resin either: devoid ofany reinforcement fibers embedded therein or reinforced with shortrandomly oriented fibers.

Further details of these and other aspects of the subject matter of thisapplication will be apparent from the detailed description includedbelow and the drawings.

DESCRIPTION OF THE DRAWINGS

Reference is now made to the accompanying drawings, in which:

FIG. 1 shows a schematic axial cross-section view of a turbofan gasturbine engine including one or more guide vanes as described herein;

FIG. 2 is a perspective view of an exemplary guide vane of the engine ofFIG. 1;

FIG. 3A is a flowchart of an exemplary method for manufacturing a guidevane;

FIG. 3B is a flowchart of an exemplary method for manufacturing a bodyof a guide vane;

FIG. 4 is a schematic representation of a process for forming acomposite vane body;

FIG. 5 is a schematic cross-sectional view of an exemplary compositevane body;

FIG. 6 is a schematic cross-sectional view of an exemplary metallicleading edge of the vane body of FIG. 5;

FIG. 7 is a schematic perspective view of another exemplary compositevane body together with an exemplary metallic sheath for application toa forward portion of the vane body;

FIG. 8 is a schematic cross-sectional view of the vane body of FIG. 7taken along line 8-8 of FIG. 8 with the metallic sheath for applicationto the forward portion of the vane body;

FIG. 9 is a schematic representation of an exemplary guide vane togetherwith mold portions for overmolding a head and a foot on a composite vanebody;

FIG. 10 is a schematic cross-sectional view of the guide vane of FIG. 9taken along line 10-10 in FIG. 9; and

FIG. 11 is a schematic representation of an exemplary anchoring featureof the composite vane body for engaging with the overmolded head orfoot.

DETAILED DESCRIPTION

The following disclosure describes constructions of composite guidevanes for gas turbine engines and methods for manufacturing suchcomposite guide vanes. In some embodiments, the methods described hereincan facilitate the manufacturing of composite guide vanes in arelatively simpler and time efficient manner using fiber-reinforcedunidirectional tape for example. In some embodiments, the methodsdescribed herein can also facilitate the retention of a metallic leadingedge on a composite guide vane.

The terms “attached”, “connected” or “coupled” may include both directattachment, connection or coupling (in which the two components contacteach other) and indirect attachment, connection or coupling (in which atleast one additional component is located between the two components).The term “substantially” as used herein may be applied to modify anyquantitative representation which could permissibly vary withoutresulting in a change in the basic function to which it is related.

Aspects of various embodiments are described through reference to thedrawings.

FIG. 1 illustrates a gas turbine engine 10 of a type preferably providedfor use in subsonic flight, generally comprising in serial flowcommunication, a fan 12 through which ambient air is propelled, amultistage compressor 14 for pressurizing the air, a combustor 16 inwhich the compressed air is mixed with fuel and ignited for generatingan annular stream of hot combustion gases, and a turbine section 18 forextracting energy from the combustion gases. Engine 10 may be of a typesuitable for use in aircraft applications. For example, engine 10 may bea turbofan (as illustrated), a turboshaft or a turboprop type of engine.

Engine 10 may also include one or more guide vanes 20 (referredhereinafter in the singular) made using one or more methods describedherein. Vane 20 may be of a type known as a “guide vane” or “statorvane” that are used to direct fluid flow toward a desired direction soas to be received into downstream rotor blades at a desired angle forexample. In some embodiments, vane 20 may be suitable for installationin a core gas path 24 of engine 10. For example, vane 20 may be an(e.g., variable orientation) inlet guide vane disposed upstream ofcompressor 14. Vane 20 may instead be disposed between two rotor stagesof compressor 14. Alternatively, vane 20 may be a bypass stator vanedisposed in a bypass duct 22 of turbofan engine 10. In variousembodiments, vane 20 may have a fixed orientation within engine 10 ormay have a controllably variable orientation within engine 10.

Engine 10 may have central axis CA corresponding to an axis of rotationof one or more spools of engine 10. Bypass duct 22 may extend generallyannularly about central axis CA. Core gas path 24 may also extendgenerally annularly about central axis CA. In some embodiments of engine10, a plurality of vanes 20 may be angularly distributed about centralaxis CA in bypass duct 22 and/or in core gas path 24.

FIG. 2 is a perspective view of an exemplary vane 20 of engine 10. Vane20 may include body 26 for interacting with a flow of fluid. Body 26 maybe made from a fiber-reinforced composite material. Vane 20 may alsoinclude metallic sheath 28 covering part of body 26. Metallic sheath 28may define leading edge 30 of vane 20. Metallic sheath 28 may provideresistance against erosion, abrasion and impact from foreign objectsthat may enter engine 10. Leading edge 30 and trailing edge 32 of vane20 are illustrated in relation to a general direction F of the flow offluid interacting with vane 20.

Vane 20 may also have foot 34 and head 36 attached to respectiveopposite ends of vane 20. In some embodiments, vane 20 may have eitherfoot 34 or head 36 for attachment of vane 20 only from one end of vane20. In relation to central axis CA of engine 10, foot 34 may be disposedat a radially inner end of body 26 of vane 20. Head 36 may be disposedat a radially outer end of body 26 of vane 20. Foot 34 may serve for theattachment of vane 20 to a radially inner support structure (e.g., innerring, shroud, engine casing, low pressure compressor housing) and head36 may be used to attach the same vane 20 to a radially outer supportstructure (e.g., outer ring, shroud, engine casing. Vane 20 may alsoinclude radially inner platform 38 and radially outer platform 40 forinteracting with the flow of fluid. Platforms 38, 40 may defineflow-interacting surfaces between guide vanes 20 that are adjacent inthe angular/circumferential direction about central axis CA. Foot 34 andhead 36 may have a generally T-shape, L-shape or any shape suitable tofacilitate installation and attachment of vane 20 within engine 10.

FIG. 3A is a flowchart of an exemplary method 100 for manufacturing vane20 or another vane made of fiber-reinforced composite material. Aspectsof method 100 may be combined with aspects of other methods and mayinclude other actions and/or aspects described herein. Aspects of method100 are further described below in relation to FIGS. 4-10. In variousembodiments, method 100 may include: receiving body 26 (shown in FIG. 2)made of a fiber-reinforced composite material (e.g., see block 102),body 26 including body mid portion 42 for interacting with a fluid andbody end portions 44 and/or 46 (shown in FIG. 7); applying metallicsheath 28 on part of body 26 (e.g., see block 104), metallic sheath 28including: sheath mid portion 48 defining a leading edge of vane 20; andsheath end portions 50 and/or 52 applied respectively to body endportions 44 and/or 46 of body 26 (shown in FIG. 7); and overmolding head36 and/or foot 34 onto body end portion(s) 44 and/or 46 of body 26 andonto sheath end portion(s) 50 and/or 52 (e.g., see block 106 and FIG.9).

FIG. 3B is a flowchart of an exemplary method 200 for manufacturing body26 of vane 20. Aspects of method 200 may be combined with aspects ofother methods and may include other actions and/or aspects describedherein. Aspects of method 200 are further described below in relation toFIGS. 4-6. In various embodiments, method 200 may include: receiving aprecursor (e.g., layup 53 shown in FIG. 4) including substantiallyparallel and non-interlaced reinforcement fibers embedded in a resin(see block 202); compression molding the precursor into preform 57 of acore of vane body 26 (see block 204 and FIG. 4); and overmolding a skinof vane body 26 on preform 57 of the core (see block 206 and FIG. 4).

In various embodiments of the methods described herein, body 26 may bemade from any suitable fiber-reinforced composite material(s) using anysuitable process. For example, body 26 may include long and/or shortfibers embedded in a suitable (e.g., polymeric) matrix material. Fibersmay, for example, be made from glass and/or carbon. Matrix materials mayinclude thermoplastic resins and/or thermosetting resins. In variousembodiments, suitable matrix materials for body 26, foot 34 and/or head36 may include polyether ether ketone (PEEK), such as product numbers450CA30 or 90HMF40 by VICTREX™, polyamide, epoxy, polyurethane, phenolicand amino resins, and bismaleimides (BMI) for example.

In some embodiments, body 26 may be made by stacking pre-impregnated(e.g., woven) tissue/fabric layers and forming such stack of layers in amold using heat. Alternatively, a resin transfer molding (RTM) processmay be used with dry tissue/fabric layers. In some embodiments, body 26may be partially or entirely made by injection molding using randomlyoriented short fibers embedded in a thermoplastic or thermosettingmatrix material. Such short fibers may have lengths of a few millimetersor less. For example, such short fibers may have lengths of about 5 mmor less. In some embodiments, such short fibers may have lengths ofabout 2 mm or less. In some embodiments, such short fibers may havelengths of about 1 mm or less. In some embodiments, body 26 may be madeof a thermosetting or thermoplastic material that is devoid of any fiberreinforcement. In some embodiments, an inner/central core of body 26may, as described below, include long continuous and optionallyunidirectional fibers embedded in a suitable thermosetting orthermoplastic matrix material. The core of body 26 may include alocation of a mid section or mid point of a mean camber line of body 26.The core of body 26 may include an innermost region of body 26 locatedat a depth from the skin of body 26.

FIG. 4 is a schematic representation of an exemplary process for formingbody 26 using layup 53 of fiber-reinforced composite sheets 54. Eachsheet 54 may be a continuous fiber-reinforced thermoplastic (CFRT)composite. For example, each sheet 54 may be a layer of continuous,substantially parallel and non-interlaced fibers pre-impregnated with athermoplastic or thermosetting resin. In some embodiments, each sheet 54may be of a type known as “unidirectional tape” or “UD tape” where asingle-layered, fiber-reinforced (e.g., thermoplastic) composite sheetin which long continuous fibers are unrolled, laid and impregnated witha (e.g., thermoplastic) resin. The UD tape may be pre-impregnated withresin. In some embodiments, each sheet 54 may be a woven tissue/fabriccloth that is pre-impregnated with resin. As non-limiting examples,sheets 54 may each have a thickness of about 0.005 inch (0.13 mm) orabout 0.010 inch (0.25 mm).

Sheets 54 may be cut automatically on a standard ply cutting table orformed using automated tape laying (ATL) equipment. Sheets 54 may bestacked manually or robotically in a mold. Sheets 54 may bepre-consolidated in a press or tack welded together before placing inthe mold. Sheets 54 may be cut and stacked based on the desired finalshape of body 26 after forming (e.g., stamping, compression molding)using mold portions 56A, 56B. Layup 53 of sheets 54 may be consolidated(e.g., at least partially densified) into a single unified precursorusing heat and pressure prior to loading such consolidated precursorinto a press defined by mold portions 56A, 56B for stamping.

The orientation of respective sheets 54 in layup 53 may be selected totailor the mechanical properties of body 26 in desired loadingdirections. In various embodiments, sheets 54 in layup 53 may havedifferent orientations (stacking angles). In some situations, the use ofsheets 54 with continuous unidirectional fibers and stacking angles mayprovide control over the final mechanical properties of body 26. In someembodiments, at least some sheets 54 and hence some of the continuousunidirectional fibers may extend continuously along substantially anentire span length SL (shown in FIG. 7) of body 26. For example, atleast some of the long fibers from sheets 54 may extend continuouslyfrom radially inner body end portion 44, through body mid portion 42 andto radially outer body end portion 46.

FIG. 4 also shows a schematic representation of an optional step ofinjection overmolding a skin over preform 57 stamped using mold portions56A, 56B and heat to obtain body 26. Preform 57 may have a substantiallysolid (i.e., non-hollow) interior. In some situations, body 26 may beformed directly by stamping (e.g., consolidated) layup 53 ofpre-impregnated sheets 54 as shown in the upper part of FIG. 4. Body 26obtained from stamping layup 53 may have acceptable dimensional accuracyfor some applications and may approximate the desired final shape ofbody 26. However, in cases where higher dimensional accuracy is requiredor body 26 includes relatively sharp edges for example, the optionalovermolding step as shown in the lower part of FIG. 4 may beadditionally carried out. In this case, the product resulting from thestamping process would be (e.g., a single) preform 57 provided to thesubsequent overmolding process. The lower part of FIG. 4 schematicallyshows body 26 as including preform 57 made from layup 53 of sheets 54 asdescribed above that is encapsulated by overmolding material 58 toachieve the desired geometry of body 26.

FIG. 4 shows schematic transverse cross-section views in relation tobody 26. Preform 57 produced by stamping layup 53 of sheets 54 usingmold portions 56A, 56B and heat may be received in molds 60A, 60B whereovermolding is carried out by the injection of overmolding material 58when molds portions 60A, 60B are closed. Preform 57 may occupy a coreregion of body 26 and overmolding material 58 may occupy a skin regionof body 26. In some embodiments, preform 57 may occupy a majority of atransverse cross-sectional area of body 26 as shown in FIG. 4.Overmolding material 58 may include a thermoplastic or thermosettingresin containing relatively short reinforcement fibers as describedabove. The fibers in overmolding material 58 may be shorter than thefibers in preform 57. Alternatively, overmolding material 58 may includea thermoplastic or thermosetting resin that is devoid of reinforcementfibers. The thermoplastic or thermosetting resin selected forovermolding material 58 may be substantially identical or chemicallycompatible with a resin used in preform 57.

In some situations, the use of optional overmolding may facilitatehigher dimensional accuracy of body 26. For example, overmoldingmaterial 58 may fill-in regions of body 26 that are not filled-in bypreform 57 and thereby substantially establish the final shape of body26. It is understood that, in some situations, sanding, grinding orother process(es) may be performed on body 26 after the stamping and/orovermolding processes illustrated in FIG. 4.

In some situations, sheath 28 may be placed into mold portions 56A, 56Btogether with layup 53, and/or into mold portions 60A, 60B together withpreform 57 and co-consolidated together with body 26 in the compositeforming operation.

FIG. 4 also shows body 26 having a substantially symmetrical airfoilshape but it is understood that body 26 may instead have a camberedairfoil shape as shown in FIG. 5.

FIG. 5 is a schematic cross-sectional view of another exemplary body 260of vane 20. Body 260 may be made according to the methods describedabove and may have a construction generally similar to that of body 26already described above. Like elements are identified using likereference numerals. Body 260 may be made from a plurality of sheet 54 ofcontinuous, substantially parallel and non-interlaced long fibersoccupying a core of body 260. The long-fiber core (e.g., preform 57 ofFIG. 4) of body 260 may optionally be encapsulated by overmoldingmaterial 58.

FIG. 6 is a schematic cross-sectional view of body 260 with an optionalmetallic leading edge 30. In some embodiments where supplemental leadingedge protection is desired, metallic sheath 28 may be applied to part ofbody 260 so as to define leading edge 30 of body 260. In someembodiments, metallic sheath 28 may be formed from sheet metal made of atitanium-based alloy, an aluminum-based alloy, a nickel-based alloy orstainless steel of the 300 series for example. Metallic sheath 28 may beformed to a desired shape by stamping for example. Alternatively,metallic sheath 28 may be formed as a coating by electrodeposition(i.e., electroforming, electroplating) or chemical vapor deposition. Forexample, metallic sheath 28 of a desired thickness may be depositeddirectly onto the applicable portion of body 260. In some embodiments,metallic sheath 28 may be deposited on another substrate of a desiredshape and then transferred (e.g., installed and adhesively bonded) ontobody 260. In some embodiments, metallic sheath 28 may be deposited as acoating based on the teachings of U.S. Patent Publication No.2012/0082553 A1 (Title: METAL ENCAPSULATED STATOR VANE), which isincorporated herein by reference. In some embodiments, metallic sheath28 may be made from a nanocrystalline metallic material. For example,metallic sheath 28 may be applied by nickel plating directly on part(e.g., the leading edge portion) of body 26. In some embodiments,metallic sheath 28 may have a thickness of between 0.001 inch (0.03 mm)and 0.015 inch (0.4 mm). In various embodiments, metallic sheath 28 mayhave a thickness of about 0.012 inch (0.3 mm), about 0.008 inch (0.2 mm)or about 0.010 inch (0.25 mm)

In some embodiments where deposition (e.g., plating) of metallic sheath28 directly onto body 26 is conducted, it may be desirable to have askin of body 26 relatively resin-rich for improved quality of plating ofthe metallic sheath 28 deposited on body 26. Accordingly, overmoldingmaterial 58 may be devoid of fiber reinforcement or may have arelatively low volume fraction of reinforcement fibers.

In some embodiments, metallic sheath 28 may be adhesively bonded to body260 using a suitable scrim-supported epoxy film adhesive or a polymericadhesive material disposed between metallic sheath 28 and body 26.Suitable surface preparation/treatment (e.g., abrasion) may be performedon surfaces of metallic sheath 28 and/or of body 26 to be bondedtogether to facilitate bonding.

FIG. 7 is a schematic perspective view of body 26 together with metallicsheath 28 to be applied to a forward portion of body 26. Metallic sheath28 may include sheath mid portion 48 for application to and wrappingaround a forward portion of body mid portion 42 so that sheath midportion 48 may define leading edge 30 (shown in FIG. 2) of vane 20.Radially inner sheath end portion 50 may be applied to radially innerbody end portion 44. Similarly, radially outer sheath end portion 52 maybe applied to radially outer body end portion 46. Body 26 may have aspan length SL.

As explained further below, radially inner sheath end portion 50 andradially inner body end portion 44 may be regions to be encapsulated byovermolded foot 34 of vane 20. Similarly, radially outer sheath endportion 52 and radially outer body end portion 46 may be regions to beencapsulated by overmolded head 36 of vane 20. The overmolding of foot34 or head 36 of vane 20 may provide mechanical retention of metallicsheath 28 onto body 26.

In some embodiments, optional anchoring features may be provided onmetallic sheath 28 and/or on body 26 for engagement with overmolded foot34 and/or head 36 to further enhance the mechanical retention ofmetallic sheath 28 and body 26 into the overmolded foot 34 and/or head36. As illustrated in FIG. 7, such anchoring features may include one ormore holes 62 formed in metallic sheath 28 and/or one or more holes 64formed in body 26. Holes 62 may be punched, drilled or machined intometallic sheath 28. Holes 64 may be drilled or machined into body 26.Alternatively, holes 64 in body 26 may be formed through the use of moldinserts or by way of the configuration of mold portions 56A, 56B and/ormold portions 60A, 60B shown in FIG. 4 depending on whether overmoldingmaterial 58 is used.

Holes 62, 64 may be of any suitable shape including circular, oval andrectangular for example. Holes 62, 64 may include recesses, elongatedchannels and/or slots for example. Hole(s) 62 may extend partially orfully through metallic sheath 28. Hole(s) 64 may extend partially orfully through body 26. Instead or in addition to holes 62, 64, anchoringfeatures may include one or more protrusions extending from metallicsheath 28 or from body 26 for engagement with foot 34 and/or head 36.

Hole(s) 62 in metallic sheath 28 and corresponding hole(s) 64 in body 26may be disposed so that after installation of metallic sheath 28 ontobody 26, hole(s) 62 may be at least partially aligned with correspondinghole(s) 64 in body 26 to permit overmolding material from foot 34 orhead 36 to enter hole(s) 64 in body 26 by passing through correspondinghole(s) 62 in metallic sheath 28. In some embodiments, hole(s) 62 inmetallic sheath 28 may be in complete alignment with respectivecorresponding hole(s) 64 in body 26. In some embodiments, hole(s) 62 inmetallic sheath 28 may be in partial alignment with (i.e., overlap)respective corresponding hole(s) 64 in body 26.

FIG. 8 is a schematic cross-sectional view of body 26 of FIG. 7 takenalong line 8-8 of FIG. 8, together with metallic sheath 28 to be appliedto the forward portion of body 26. In some embodiments, body 26 may beformed to define joggle 66 to accommodate the presence of metallicsheath 28 and provide a substantially flush (e.g., even or leveled)transition between an upstream outer surface of metallic sheath 28 and adownstream outer surface of body 26. Joggle 66 may be an offset formedon an outer surface of body 26. A size of such offset may be determinedbased on a thickness of metallic sheath 28 and a bonding substancedisposed between metallic sheath 28 and body 26. In some embodiments,the size of the offset provided by joggle 66 may be between 0.010 inch(0.25 mm) and 0.012 inch (0.30 mm). Joggle 66 may provide a steptransition between a recessed forward surface of body 26, to whichmetallic sheath 28 may be bonded, and the remainder of body 26.

FIG. 9 is a schematic representation of an exemplary vane 20 illustratedtogether with mold portions 68A, 68B for injection overmolding head 36and mold portions 68C, 68D for injection overmolding foot 34 on body 26and on metallic sheath 28. Head 36 and foot 34 may be overmolded usingovermolding material 70. Overmolding material 70 may include athermoplastic or thermosetting resin containing relatively shortreinforcement fibers as described above. The fibers in overmoldingmaterial 70 may be shorter than the fibers in preform 57 (shown in FIG.4). Alternatively, overmolding material 70 may include a thermoplasticor thermosetting resin that is devoid of reinforcement fibers. Thethermoplastic or thermosetting resin selected for overmolding material70 may be substantially identical or chemically compatible with a resinused in body 26.

FIG. 9 shows head 36 and foot 34 as being transparent for the purpose ofillustrating the components encapsulated into head 36 and foot 34 by wayof overmolding. For example, radially inner sheath end portion 50 andradially inner body end portion 44 may be disposed inside of overmoldedfoot 34 and mechanically retained inside of foot 34. Similarly, radiallyouter sheath end portion 52 and radially outer body end portion 46 maybe disposed inside of overmolded head 36 and mechanically retainedinside of head 36.

FIG. 10 is a schematic cross-sectional view of vane 20 of FIG. 9 takenalong line 10-10 in FIG. 9. Radially outer sheath end portion 52 andradially outer body end portion 46 are shown as being encapsulated byovermolded head 36 and mechanically retained inside of head 36. Optionalholes 62, 64 are shown as being filled with overmolding material 70 usedto form head 36. In some embodiments, the presence of holes 62, 64 mayprovide stronger retention of sheath end portion 52 and radially outerbody end portion 46 into head 36 by providing further mechanicalengagement (e.g., anchoring, interlocking) between head 36 and sheathend portion 52, and also between head 36 and radially outer body endportion 46.

FIG. 11 is a schematic representation of another exemplary type ofanchoring feature that may be used instead of, or in addition to holes64. Such anchoring feature may include one or more tabs 72 projectingoutwardly from body end portion 46 and for engaging with overmoldingmaterial 70 of head 36 for example. Tab 72 may be made by havingcomposite sheet(s) 54 extend outwardly from layup 53 and molded into tab72 during the forming of body 26 or preform 57 shown in FIG. 4. Theformation of one or more tabs 72 may require a subsequentforming/molding of sheets 54 required to form tab 72 on preform 57 orbody 26 in addition to the molding step shown in the upper portion ofFIG. 4.

The embodiments described in this document provide non-limiting examplesof possible implementations of the present technology. Upon review ofthe present disclosure, a person of ordinary skill in the art willrecognize that changes may be made to the embodiments described hereinwithout departing from the scope of the present technology. Yet furthermodifications could be implemented by a person of ordinary skill in theart in view of the present disclosure, which modifications would bewithin the scope of the present technology.

What is claimed is:
 1. A method of manufacturing a composite guide vaneof a gas turbine engine, the method comprising: receiving a body made ofa fiber-reinforced composite material, the body including a body midportion for interacting with a fluid and a body end portion; applying ametallic sheath on part of the body, the metallic sheath including: asheath mid portion applied to the body mid portion to define a leadingedge of the guide vane; and a sheath end portion applied to the body endportion; forming a hole in the sheath end portion; overmolding a head ora foot of the guide vane onto the body end portion and onto the sheathend portion; and receiving overmolding material into the hole during theovermolding.
 2. The method as defined in claim 1, wherein: the body endportion is a first body end portion; the body includes a second body endportion opposite the first body end portion; the sheath end portion is afirst sheath end portion; the metallic sheath includes a second sheathend portion applied to the second body end portion; the method includes:overmolding the head onto the first body end portion and onto the firstsheath end portion; and overmolding the foot onto the second body endportion and onto the second sheath end portion.
 3. The method as definedin claim 1, wherein: the hole in the sheath end portion is a sheathhole; the method comprises: forming a body hole in the body end portion;and receiving overmolding material into the body hole during theovermolding.
 4. The method as defined in claim 3, wherein the body holeis at least partially aligned with the sheath hole.
 5. The method asdefined in claim 1, wherein: the body end portion is a first body endportion; the body includes a second body end portion opposite the firstbody end portion; the body mid portion is disposed between the firstbody end portion and the second body end portion; a core of the bodyincludes substantially parallel fibers embedded in a matrix material;and at least some of the substantially parallel fibers extendcontinuously from the first body end portion to the second body endportion.
 6. The method as defined in claim 5, wherein: a skin of thebody includes randomly oriented fibers embedded in another matrixmaterial; and the randomly oriented fibers are shorter than thesubstantially parallel fibers.
 7. The method as defined in claim 6,wherein the body end portion includes an anchoring feature engaged withthe head or foot.
 8. The method as defined in claim 1, wherein thesheath end portion includes an anchoring feature engaged with the heador foot.
 9. The method as defined in claim 1, wherein applying themetallic sheath on part of the body includes nickel plating the metallicsheath on part of the body.
 10. A method of manufacturing a compositeguide vane of a gas turbine engine, the method comprising: receiving alayup of fiber-reinforced composite sheets of continuous, substantiallyparallel and non-interlaced fibers impregnated with a thermoplasticresin; forming a vane body from the layup of sheets, the vane bodyincluding a body mid portion for interacting with a fluid and a body endportion; applying a metallic sheath on part of the vane body, themetallic sheath defining a leading edge of the guide vane; andovermolding a head or a foot of the guide vane onto part of the vanebody and onto part of the metallic sheath, wherein forming the vane bodyincludes: stamping the layup of sheets into a preform of a core of thevane body; and then overmolding a skin on the preform.
 11. A guide vanefor a gas turbine engine, the guide vane comprising: a body made of afiber-reinforced composite material, the body including a body midportion for interacting with a fluid and a body end portion; a metallicsheath applied to part of the body, the metallic sheath including: asheath mid portion applied to the body mid portion and defining aleading edge of the guide vane; and a sheath end portion applied to thebody end portion; and a head or foot overmolded onto the body endportion and onto the sheath end portion, wherein the sheath end portionincludes a hole and overmolding material of the head or foot extendsinto the hole.
 12. The guide vane as defined in claim 11, comprisingboth the head and the foot, wherein: the body end portion is a firstbody end portion; the body includes a second body end portion oppositethe first body end portion; the sheath end portion is a first sheath endportion; the metallic sheath includes a second sheath end portionapplied to the second body end portion; the head is overmolded onto thefirst body end portion and onto the first sheath end portion; and thefoot is overmolded onto the second body end portion and onto the secondsheath end portion.
 13. The guide vane as defined in claim 12, whereinthe body includes a joggle accommodating the metallic sheath.
 14. Theguide vane as defined in claim 11, wherein the sheath end portionincludes an anchoring feature engaged with the head or foot.
 15. Theguide vane as defined in claim 11, wherein the body end portion includesan anchoring feature engaged with the head or foot.
 16. The guide vaneas defined in claim 11, wherein: the hole is a through sheath hole; thebody end portion includes a body hole at least partially aligned withthe sheath hole; and overmolding material of the head or foot extendsinto the sheath hole and into the body hole.
 17. The guide vane asdefined in claim 11, wherein: the body end portion is a first body endportion; the body includes a second body end portion opposite the firstbody end portion; the body mid portion is disposed between the firstbody end portion and the second body end portion; a core of the bodyincludes long fibers embedded in a matrix material; and a skin of thebody includes randomly oriented short fibers embedded in another matrixmaterial.
 18. A guide vane for a gas turbine engine, the guide vanecomprising: a body made of a fiber-reinforced composite material, thebody including a body mid portion for interacting with a fluid and abody end portion; a metallic sheath applied to part of the body, themetallic sheath including: a sheath mid portion applied to the body midportion and defining a leading edge of the guide vane; and a sheath endportion applied to the body end portion; and a head or foot overmoldedonto the body end portion and onto the sheath end portion, wherein: thebody end portion is a first body end portion; the body includes a secondbody end portion opposite the first body end portion; the body midportion is disposed between the first body end portion and the secondbody end portion; a core of the body includes long fibers embedded in amatrix material; and a skin of the body includes randomly oriented shortfibers embedded in another matrix material.